Formation method of chip package

ABSTRACT

A method for forming a chip package is provided. The method includes forming a plurality of conductive structures over a carrier substrate. The method also includes disposing a semiconductor die over the carrier substrate such that the conductive ti structures surround the semiconductor die. The method further includes disposing a shielding element over the semiconductor die and the conductive structures. The shielding element is electrically connected to the conductive structures.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Divisional of U.S. patent application Ser. No.16/284,630, filed Feb. 25, 2019, which claims the benefit of U.S.Provisional Application No. 62/725,675, filed Aug. 31, 2018, theentirety of which is incorporated by reference herein

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to devices and methods for forming a chippackage.

Description of the Related Art

Semiconductor devices are used in a variety of electronic applications,such as personal computers, cell phones, digital cameras, and otherelectronic equipment. The fabrication of the semiconductor devicesinvolves sequentially depositing insulating or dielectric layers,conductive layers, and semiconductor layers over a semiconductorsubstrate, and patterning the various material layers using lithographyand etching processes to form circuit components and elements on thesemiconductor substrate.

The semiconductor industry continues to improve the integration densityof various electronic components (e.g., transistors, diodes, resistors,capacitors, etc.) by continual reductions in minimum feature size, whichallows more components to be integrated into a given area. The number ofinput and output (I/O) connections is significantly increased. Smallerpackage structures, which utilize less area or have lower heights, aredeveloped to package the semiconductor devices.

New packaging technologies have been developed to improve the densityand functionality of semiconductor devices. These relatively new typesof packaging technologies for semiconductor devices face manufacturingchallenges.

BRIEF SUMMARY OF THE INVENTION

According to some embodiments, a method for forming a chip package isprovided. The method includes forming a plurality of conductivestructures over a carrier substrate. The method also includes disposinga semiconductor die over the carrier substrate such that the conductivestructures surround the semiconductor die. The method further includesdisposing a shielding element over the semiconductor die and theconductive structures. The shielding element is electrically connectedto the conductive structures.

According to some embodiments, a method tier forming a chip package isprovided. The method includes forming a plurality of conductivestructures over a redistribution structure. The method also includesdisposing a semiconductor die over the redistribution structure suchthat the conductive structures surround the semiconductor die. Two ofthe conductive structures are separated from each other by a distance,and the distance is smaller than half a wavelength of an electromagneticwave generated by the semiconductor die.

According to some embodiments, a method for forming a chip package isprovided. The method includes disposing a first semiconductor die and asecond semiconductor die over the a redistribution structure. The methodalso includes disposing a plurality of conductive structures over theredistribution structure. The conductive structures surround an areawhere the first semiconductor die is positioned, and the secondsemiconductor die is positioned outside of the area.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It shouldbe noted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIGS. 1A-1F are cross-sectional views of various stages of a process forforming a chip package, in accordance with some embodiments.

FIGS. 2A-2E are cross-sectional views of various stages of a process forforming a chip package, in accordance with some embodiments.

FIG. 3 is a top view of an intermediate stage of a process for forming achip package, in accordance with some embodiments.

FIG. 4 is a top view of an intermediate stage of a process for forming achip package, in accordance with some embodiments.

FIG. 5 is a top view of an intermediate stage of a process for forming achip package, in accordance with some embodiments.

FIG. 6 is a top view of an intermediate stage of a process for forming achip package, in accordance with some embodiments.

FIG. 7 is a top view of an intermediate stage of a process for forming achip package, in accordance with some embodiments.

FIGS. 8A-8C are cross-sectional views of various stages of a process forforming a chip package, in accordance with some embodiments.

FIG. 9 is a cross-sectional view of a chip package, in accordance withsome embodiments.

FIG. 10 is a cross-sectional view of a chip package, in accordance withsome embodiments.

FIG. 11 is a cross-sectional view of a chip package, in accordance withsome embodiments.

FIG. 12 is a cross-sectional view of a chip package, in accordance withsome embodiments.

FIG. 13 is a cross-sectional view of a chip package, in accordance withsome embodiments.

FIG. 14 is a top view of a shielding element of a chip package, inaccordance with some embodiments.

FIG. 15 is a top view of a shielding element of a chip package, inaccordance with some embodiments.

DETAILED DESCRIPTION OF THE INVENTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and; or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Embodiments of the disclosure may be applied in 3D packaging or 3D ICdevices. Other features and processes may also be included. For example,testing structures may be included to aid in the verification testing ofthe 3D packaging or 3DIC devices. The testing structures may include,for example, test pads formed in a redistribution layer or on asubstrate that allows the testing of the 3D packaging or 3DIC, the useof probes and/or probe cards, and the like. The verification testing maybe performed on intermediate structures as ;ell as the final structure.Additionally, the structures and methods disclosed herein may be used inconjunction with testing methodologies that incorporate intermediateverification of known good dies to increase the yield and decreasecosts.

Some embodiments of the disclosure are described. Additional operationscan be provided before, during, and/or after the stages described inthese embodiments. Some of the stages that are described can be replacedor eliminated for different embodiments. Additional features can beadded to the semiconductor device structure. Some of the featuresdescribed below can be replaced or eliminated for different embodiments.Although some embodiments are discussed with operations performed in aparticular order, these operations may be performed in another logicalorder.

FIGS. 1A-1F are cross-sectional views of various stages of a process forforming a chip package, in accordance with some embodiments. As shown inFIG. 1A, an interconnection structure 102 is formed over the carriersubstrate 100, in accordance with some embodiments. The interconnectionstructure 102 may be used as a redistribution structure for routing. Theinterconnection structure 102 includes multiple insulating layers 104and multiple conductive features 106, as shown in FIG. 1A. Theconductive features 106 may include conductive lines, conductive vias,and/or conductive pads. The interconnection structure 102 also includesconductive features 107 that are used to hold or receive other elementssuch as conductive pillars or semiconductor dies.

In some embodiments, some of the conductive features 107 are exposed ator protrude from the topmost surface of the insulating layers 104. Theexposed or protruding conductive features 107 may serve as bonding padswhere conductive bumps (such as tin-containing solder bumps) and/orconductive pillars (such as copper pillars) will be formed later.

The insulating layers 104 may be made of or include one or more polymermaterials. The polymer materials) may include polybenzoxazole (PBO),polyimide (PI), one or snore other suitable polymer materials, or acombination thereof. In some embodiments, the polymer material isphotosensitive. In some embodiments, some or all of the insulatinglayers 104 are made of or include dielectric materials other thanpolymer materials. The dielectric material may include silicon oxide,silicon carbide, silicon nitride, silicon oxynitride, one or more othersuitable materials, or a combination thereof.

The conductive features 106 may include conductive lines providingelectrical connection in horizontal directions and conductive viasproviding electrical connection in vertical directions. The conductivefeatures 106 may be made of or include copper, aluminum, gold, cobalt,titanium, graphene, one or more other suitable conductive materials, ora combination thereof.

The formation of the interconnection structure 102 may involve multipledeposition or coating processes, multiple patterning processes, and/ormultiple planarization processes.

The deposition or coating processes may be used to form insulatinglayers and/or conductive layers. The deposition or coating processes mayinclude a spin coating process, an electroplating process, anelectroless process, a chemical vapor deposition (CVD) process, aphysical vapor deposition (PAID) process, an atomic layer deposition(ALD) process, one or more other applicable processes, or a combinationthereof.

The patterning processes may be used to pattern the formed insulatinglayers and/or the formed conductive layers. The patterning processes mayinclude a photolithography process, an energy beam drilling process(such as a laser beam drilling process, an ion beam drilling process, oran electron beam drilling process), an etching process, a mechanicaldrilling process, one or more other applicable processes, or acombination thereof.

The planarization processes may be used to provide the formed insulatinglayers and/or the formed conductive layers with planar top surfaces tofacilitate subsequent processes. The planarization processes may includea mechanical grinding process, a chemical mechanical polishing (CMP)process, one or more other applicable processes, or a combinationthereof.

However, marry variations and/or modifications can be made toembodiments of the disclosure in some other embodiments, theinterconnection structure 102 is not formed.

Afterwards, conductive structures 108 and 108S are formed over some ofthe conductive features 107, as shown in FIG. 1A in accordance with someembodiments. In some embodiments, the conductive structures 108 are usedfor signal transmission. In some embodiments, the conductive structures108S are used as a shielding structure capable of preventingelectromagnetic interference (EMI) caused by a semiconductor die thatwill be disposed later.

In some embodiments, the conductive structures 108 and 108S areconductive pillars. In some embodiments. the conductive structures 108and 108S have substantially straight sidewalls. The sidewalls of theconductive structures 108 and 108S may be substantially perpendicular tothe top surface of the camel substrate 100. The conductive structures108 and 108S may be made of or include copper, aluminum, titanium,cobalt, gold, tin-containing alloys, one or more other suitablematerials, or a combination thereof.

The conductive structures 108 and 108S may be formed using anelectroplating process, an electroless plating process, a PVD process, aCVD process, one or more other applicable processes, or a combinationthereof. In some other embodiments, the conductive structures 108 and108S are picked and placed onto the exposed conductive features 107.Tin-containing solder elements may be used to affix the conductivestructures 108 and 108S. In some embodiments, the conductive structures108 and 108S are simultaneously formed. In some other embodiments, theconductive structures 108 and 108S are separately formed. For example,the conductive structures 108 are formed before the conductivestructures 108S. Alternatively, the conductive structures 108S areformed before the conductive structures 108.

As shown in FIG. 1B semiconductor device such as a semiconductor dies110A and 110B are disposed over the carrier substrate 100, in accordancewith some embodiments, The semiconductor die 110B is disposed outside ofan area that is surrounded by the conductive structures 108S, as shownin FIG. 1B.

In some embodiments, the semiconductor dies 110A and 110B are disposedonto some of the exposed conductive features 107. The semiconductor dies110A and 110B may be a system-on-chip (SoC) chip. In some otherembodiments, the element 110A or 110B is a system on integrated circuit(SoIC) device that includes two or more chips with integrated function.In these cases, the reference number “110A or 110B” is used to designatea semiconductor device. The semiconductor device may include one die,multiple dies, or system-on-integrated-circuit chip device. For example,one or two of the elements 110A and 110B include a stack of multiplesemiconductor dies.

In some embodiments, the semiconductor die 110A includes radio-frequencyintegrated circuits (RF-IC) such as radio-frequency front end (RFFE)modules. The operation frequency of the semiconductor die 110A is in theradio-frequency range. An electromagnetic wave having the wavelengthcorresponding to the operation frequency may be generated by thesemiconductor die 110A during operation.

For example, the operation frequency of the semiconductor die 110A maybe about 28 GHz. In these cases, electromagnetic wave having awavelength of about 10.7 mm may be generated by the semiconductor die110A during operation. For example, the electromagnetic wave may betransmitted through the protective substrate 20. In some cases, thegenerated electromagnetic wave may negatively affect the operation ofnearby device elements (such as the semiconductor die 110B or motherdevice element in another nearby chip package). In some embodiments,shielding structures and/or shielding elements are fort ed later toprevent the generated electromagnetic wave from reaching nearby deviceelements and affecting the operation of the nearby device elements.

In sonic embodiments, the semiconductor die 110B includes low-noiseamplifier (LNA) modules, low-loss filter modules, power amplifier (PA)modules, baseband modules, power management integrated circuit (PMIC),memory modules, micro-electromechanical system (MEMS) modules,nano-electromechanical systems (NEMS) modules, one or more othersuitable circuits, or a combination thereof. In some embodiments, thesemiconductor die 110B does not include any radio-frequency integratedcircuit.

In some embodiments, the semiconductor dies 110A and 110B are disposedover the interconnection structure 102 formed over the carrier substrate100. In some embodiments, the semiconductor dies 110A and 110B arebonded to some of the conductive features 107 of the interconnectionstructure 102 through bonding structures 114. The bonding structures 114may physically and electrically connect some of the conductive features107 and conductive features 112 of the semiconductor dies 110A and 110B.The conductive features 112 of the semiconductor dies 110A and 110B mayinclude conductive pads, conductive pillars, conductive traces, or thelike.

In some embodiments, the bonding structures 114 are or include solderbumps such as tin-containing solder bumps. The tin-containing solderbumps may further include copper, silver, gold, aluminum, lead, one ormore other suitable materials, or a combination thereof. In someembodiments, the tin-containing solder bump is lead free. The formationof the bonding structures 114 may involve one or more reflow processesand/or one or more plating processes.

As show n in FIG. 1B, underfill elements 116 are formed to protect thebonding structures 114, in accordance with some embodiments. Theunderfill elements 116 are made of or include one or more polymermaterials. The underfill elements 116 may include an epoxy-based resin.In some embodiments, the underfill elements 116 further include fillersdispersed in the epoxy-based resin. In some embodiments, the formationof the underfill elements 116 involves an injecting process, adispensing process, a film lamination process, an application process,one or more other applicable processes, or a combination thereof. Insome embodiments, a thermal curing process is then used to complete theformation of the underfill elements 116.

As shown in FIG. 1C a protective substrate 20 is provided or receivedand is ready to be bonded onto the conductive structures 108 and 108S,in accordance with some embodiments. In some embodiments, the protectivesubstrate 20 includes a board 200 and a shielding element 208. In someembodiments, the protective substrate 20 also includes conductiveelements 214 and 214S. In some embodiments, the protective substrate 20includes antenna elements, main patch elements, parasitic patchelements, ground elements, one or more other suitable elements, or acombination thereof.

FIGS. 2A-2E are cross-sectional views of various stages of a process forforming a chip package, in accordance with some embodiments. In someembodiments, the protective substrate 20 in FIG. 1C is formed using theprocess illustrated in FIGS. 2A-2E.

As shown in FIG. 2A, conductive films 202A and 202B are formed overopposite surfaces of the board 200, in accordance with some embodiments.The conductive films 202A and 202B may be used to assist in a subsequentelectroplating process. The board 200 may be made of or include apolymer material, a ceramic material, a metal material, a semiconductormaterial, one or more other suitable materials, or a combination thereofFor example, the board 200 includes resin, prepreg, glass, and/orceramic.

The conductive films 202A and 202B may be made of or include aluminum,copper, cobalt, gold, titanium, one or more other suitable materials, ora combination thereof. The conductive films 202A and 202B may be formedusing a thermal compression process, a PVD process, a CND process, alamination process, a printing process, one or more other applicationprocesses, or a combination thereof.

However, embodiments of the disclosure are not limited thereto. In someother embodiments, the conductive films 202A and 202B are not formed.

As shown in FIG. 2B, the conductive films 202A and 202B and the board200 are partially removed to form openings 204, in accordance with someembodiments. In some embodiments, the openings 204 completely penetratethrough the board 200 and the conductive films 202A and 202B. Theopenings 204 may be formed using an energy beam drilling process, amechanical drilling process, photolithography and etching processes, oneor more other applicable processes, or a combination thereof. The energybeam drilling process may include a laser drilling process, an ion beamdrilling process, an electron beam drilling process, a plasma beamdrilling process, one or more other applicable processes, or acombination thereof.

Afterwards, a seed layer is deposited over the structure shown in FIG.2B in accordance with some embodiments. The seed layer extends over theconductive films 202A and 202B. The seed layer further extends oversidewalk of the opening 204. Afterwards, patterned photoresist layersare formed on the seed layer. The patterned photoresist layers haveopenings that partially expose the seed layer and define patterns ofconductive features to be formed on the board 200 later. Then, one ormore conductive materials are electroplated on the portions of the seedlayer not covered by the patterned photoresist layers. Afterwards, thepatterned photoresist layers are removed. One or more etching processesare used to remove the portions of the seed laser originally covered bythe patterned photoresist layers. The portions of the conductive films202A and 202B originally covered by the patterned photoresist layers arealso removed during the one or more etching processes.

As a result, the board 200 is partially exposed, as show t in FIG. 2C,in accordance with some embodiments. The remaining portions of theelectroplated conductive material, the remaining seed layer, and theremaining conductive films 202A and 202B together form conductivefeatures 206 with desired patterns. Some of the conductive features 206penetrate through the board 200 to provide electrical connectionsbetween elements to be positioned on the opposite surfaces of the board.

In some embodiments, some of the conductive features 206 together formone (or more) antenna element 207, as shown in FIG. 2C. The pattern ofthe antenna element 207 may be fine-tuned to provide desired functions.In some embodiments, the antenna element 207 is a patch antenna that isused to receive and/or transmit electromagnetic signals in normaldirection. In some other embodiments. the antenna element 207 is anend-fire antenna that is used to receive and/or transmit electromagneticsignals in side direction. In some embodiments, multiple antennaelements with different functions are formed over the board 200.

As shown in FIG. 2C, a shielding element 208 is formed over the bottomsurface of the board 200, in accordance with some embodiments. In someembodiments, one or more of the conductive features 206 form theshielding element 208. In these cases, the antenna element 207 and theshielding element 208 are formed from patterning the same conductivematerial layer. The antenna element 207 and the shielding element 208are made of the same material. In some other embodiments, the. shieldingelement 208 and the conductive features 206 are formed using differentprocesses. In some embodiments, the shielding element 208 and theantenna element 207 are made of different materials.

As shown in FIG. 2D, protective layers 210 and 212 are formed over theopposite surfaces of the board 200, in accordance with some embodiments.The protective layers 210 and 212 may be made of or include epoxy-basedresin, polyimide, polybenzoxazole, one or t lore other suitablematerials, or a combination thereof. The protective layers 210 and 212have multiple openings that partially expose the conductive features206. For example, the antenna element 207 and the shielding element 208are partially exposed, as shown in FIG. 2D. The formation of theprotective layers 210 and 212 may involve a coating process and aphotolithography process. The coating process may include a spin coatingprocess, a spray coating process, a lamination process, one or moreother applicable processes, or a combination thereof.

As shown in FIG. 2E, conductive bumps 214 are formed over some of theconductive features 206, in accordance with some embodiments. In someembodiments, conductive bumps 214S are formed over the exposed portionsof the shielding element 208, as shown in FIG. 2E. In some embodiments,the conductive bumps 214 and 214S are made of the same material. In someembodiments, the conductive bumps 214 and 214S are tin-containing solderelements. The tin-containing solder elements may further include copper,silver, gold, aluminum, lead, one or more other suitable materials, or acombination thereof. In some embodiments, the tin-containing solderelements are lead free. The formation of the conductive bumps 214 and214S may involve one or more plating processes (such as electroplatingprocesses) and/or one or more reflow processes. Afterwards, asingulation process may be carried out to saw through the structure. Asa result, multiple substrates 20 are formed. In FIG. 2E, one of thesubstrates 20 is shown.

Referring back to FIG. 1C, the protective substrate 20 is positioned toallow the conductive elements 214 to be substantially aligned with theconductive structures 108, in accordance with some embodiments. Theprotective substrate 20 is also positioned to allow the conductiveelements 214S to be substantially aligned with the conductive structures108S. As mentioned above, in some embodiments, the conductive elements214 and 214S are tin-containing solder elements which may facilitate asubsequent bonding process.

As shown in FIG. 1D, the protective substrate 20 is bonded to theconductive structures 108 and 108S, in accordance with some embodiments.In some embodiments, the protective substrate 20 is bonded to theconductive structures 108 and 108S through the conductive bumps 214 and214S. As mentioned above, in some embodiments, the conductive humps 214and 214S are tin-containing solder elements. A reflow process may beused to bond the conductive bumps 214 and 214S to the conductivestructures 108 and 108S, respectively. In some embodiments, after theprotective substrate 20 is bonded onto the conductive structures 214 and214S, the shielding element 208 is also disposed over the semiconductordie 110A. The shielding element 208 is electrically connected to theconductive structures 108S through the conductive bumps 214S.

The conductive structures 108S (which together function as a shieldingstructure) and the shielding element 208 may be used to prevent theelectromagnetic wave generated by the semiconductor die 110A fromaffecting the operation of nearby device elements, such as thesemiconductor die 110B or another nearby package. In some other caseswhere the conductive structures 108S or the shielding element 208 arenot formed, the electromagnetic wave ;venerated by the semiconductor die110A may negatively affect the operation of the semiconductor die 110Bor the operation of another nearby device elements.

FIG. 3 is a top view of an intermediate stage of a process for forming achip package, in accordance with some embodiments. In some embodiments,FIG. 3 shows the top view of the structure shower in FIG. 1B. Forsimplicity and clarity, only the shielding structure, the topmostinsulating layer 104, and the semiconductor dies 110A and 110B areillustrated.

As shown in FIG. 3, the conductive structures 108S surround or encirclea space where the semiconductor die 110A is positioned, in accordancewith some embodiments. The semiconductor die 110B is disposed outside ofan area that is surrounded by the conductive structures 108S. In someembodiments, the top view of each of the conductive structures 108S hasa circular profile. The conductive structures 108S together form ashielding structure. The shielding structure has multiple openings Gthat expose the space containing the semiconductor die 110A. Therefore,during a subsequent formation process of a protective layer, a portionof the protective layer could penetrate through the openings G tosurround and protect the semiconductor die 110A.

In some embodiments, two nearby conductive structures 108S are separatedfrom each other by a distance W1, as shown in FIG. 3. The distance W1may be in a range from about 10 μm to half the wavelength of theelectromagnetic wave generated by the semiconductor die 110A. Each ofthe conductive structures 108S has a width W2, as shown in FIG. 3. Insome embodiments, the width W2 is in a range from about 5 μm to aboutten times the distance W1 to ensure sufficient shielding efficiency.

In some cases, if the distance W1 is smaller than about 10 μm, thesubsequently formed protective layer might not be able to penetratethrough the openings to protect the semiconductor die 110A.Alternatively, the subsequently formed protective layer might not beable to completely surround and protect the semiconductor die 110A. Thereliability and quality of the chip package may be negatively affected.

In some other cases, if the distance W1 is greater than half thewavelength of the electromagnetic wave generated by the semiconductordie 110A, the shielding efficiency may not be sufficient. As a result,the electromagnetic wave generated by the semiconductor die 110A duringoperation may not be well shielded and may reach the nearby deviceelements (such as the semiconductor die 110B or another e package) tonegatively affect the operation.

For example, the operation frequency of the semiconductor die 110A maybe about 28 GHz. In these cases, electromagnetic wave having awavelength of about 10.7 mm may be generated by the semiconductor die110A during operation. In these cases, half the wavelength of theelectromagnetic wave generated by the semiconductor die 110A is about5.35 mm. In some embodiments, the distance W1 is designed to be in arange from about 10 μm to about 5.35 mm to ensure sufficient shieldingefficiency and to ensure sufficient protection of the semiconductor die110A. In some embodiments, the width W2 is designed to be in a rangefrom about 5 μm to about 53.5 mm.

However, embodiments of the disclosure are not limited thereto. Manyvariations and/or modifications can be made to embodiments of thedisclosure. The top views of different conductive structures may havedifferent shapes.

FIG. 4 is a top view of an intermediate stage of a process for forming achip package, in accordance with some embodiments. In some embodiments,FIG. 4 shows the top view of the structure shown in FIG. 1B. Forsimplicity and clarity, only the shielding structure, the topmostinsulating layer 104, and the semiconductor dies 110A and 110B areillustrated.

As shown in FIG. 4, the semiconductor die 110A is surrounded by not onlythe conductive structures 108S but also the conductive walls 108S′, inaccordance with some embodiments. In some embodiments, a lateralextending direction of the conductive wails 108S′ is substantiallyparallel to a lateral extending direction of the side of thesemiconductor die 110A. The conductive structures 108S and theconductive walls 108S′ together function as a shielding structure.

The shielding structure has multiple openings G that expose the spacecontaining the semiconductor die 110A. Therefore, during a subsequentformation process of a protective layer, a portion of the protectivelayer could penetrate through the openings G to surround and protest thesemiconductor die 110A. In some embodiments, the distance between anynearby conductive structures 108S and/or conductive walls 108S′ is in arange from about 10 μm to half the wavelength of the electromagneticwave generated by the semiconductor die 110A.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 5 is a top view of an intermediate stage of a processfor forming a chip package, in accordance with some embodiments. In someembodiments, FIG. 5 shows the top view of the structure shown in FIG.1B. For simplicity and clarity, only the shielding structure, thetopmost insulating layer 104, and the semiconductor dies 110A and 110Bare illustrated.

In some embodiments, the top view of each of the conductive structures108S has an oval profile, as shown in FIG. 5. The conductive structures108S together form a shielding structure. The shielding structure hasmultiple openings G that expose the space containing the semiconductordie 110A. Therefore, during a subsequent formation process of aprotective layer, a portion of the protective layer could penetratethrough the openings G to surround and protect the semiconductor die110A. In some embodiments, the distance between any nearby conductivestructures 108S and/or conductive walls 108S′ is in a range from about10 μm to half the wavelength of the electromagnetic leave generated bythe semiconductor die 110A.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 6 is a top view of an intermediate stage of a processfor forming a chip package, in accordance with some embodiments. In someembodiments, FIG. 6 shows the top view of the structure shown in FIG.1B. For simplicity and clarity, only the shielding structure, thetopmost insulating layer 104, and the semiconductor dies 110A and 110Bare illustrated.

In some embodiments, the semiconductor die 110 A is surrounded by asingle conductive wall 108S″ that functions as a shielding structure.The shielding structure has an openings G that expose the spacecontaining the semiconductor die 110A. Therefore, during a subsequentformation process of a protective layer, a portion of the protectivelayer could penetrate through the openings G to surround and protect thesemiconductor die 110A. In some embodiments, the width of the opening Gis in a range from about 10 μm to half the wavelength of theelectromagnetic wave generated by the semiconductor die 110A.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 7 is a top view of an intermediate stage of a processfor forming a chip package, in accordance with some embodiments. In someembodiments, FIG. 7 shows the top view of the structure shown in FIG.1B. For simplicity and clarity, only the shielding structure, thetopmost insulating layer 104, and the semiconductor dies 110A and 110Bare illustrated.

In some embodiments, the top view of each of the conductive structures108S has an oval profile, as shown in FIG. 7. In some embodiments, thelong axis of one or each of the conductive structures 108S extends alonga direction that is substantially parallel to the extending direction ofthe corresponding side of the semiconductor die 110A, as shown in FIG.7.

The conductive, structures 108S together form a shielding structure. Theshielding structure has multiple openings G that expose the spacecontaining the semiconductor die 110A. Therefore, during a subsequentformation process of a protective layer, a portion of the protectivelayer could penetrate through the openings G to surround and protect thesemiconductor die 110A. In some embodiments, a distance between anynearby conductive structures 108S and/or conductive walls 108S′ is in arange from about 10 μm to half the wavelength of the electromagneticwave generated by the semiconductor die 110A.

In some embodiments, as mentioned above, the shielding structure and theshielding element 208 are electrically connected to each other.Therefore, the shielding structure (including the conductive structures108S and/or the conductive walls 108S′) and the shielding element 208may together reduce or prevent the electromagnetic interference (EMI)effect caused by the semiconductor die 110A. Many variations and/ormodifications can be made to the shielding element 208, in accordancewith some embodiments. For example, the top view of the shieldingelement 208 has many variations.

FIG. 14 is a top view of a shielding element of a chip package, inaccordance with some embodiments. In some embodiments, FIG. 14 shows thetop view of the shielding element 208 shown in FIG. 1D. In someembodiments, the shielding element 208 is a conductive plate. In someembodiments, the conductive plate has no opening or through-hole. Insome embodiments, the shielding element 208 covers the shieldingstructure (including the conductive structures 108S and/or theconductive walls 108S′) and the semiconductor die 110A.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 15 is a top view of a shielding element of a chippackage, in accordance with some embodiments. In some embodiments, theshielding element 208 is a conductive mesh with many through-holes G′.In some embodiments, each of the through-holes G′ is designed to have awidth W3 that is in a range from about 10 μm to half the wavelength ofthe electromagnetic Nave generated by the semiconductor die 110A.Therefore, the shielding efficiency of the shielding element 208 isensured.

In some other embodiments, the shielding element 208 includes acombination of a conductive plate and a conductive mesh. For example, aportion of the shielding element 208 is a conductive plate withoutthrough-holes G′, and another portion of the shielding element 208 is aconductive mesh with through-holes G′.

Referring to FIG. 1E, a protective layer 118 is formed to surround thesemiconductor dies 110A and 110B and the conductive structures 108S and108, in accordance with some embodiments. In some embodiments, theprotective layer 118 penetrates through the openings G (as shown in FIG.3, 4, 5. 6, or 7) between the conductive structures 108S to surround thesemiconductor die 110A. In some embodiments, the protective layer 118 isin direct contact with the conductive structures 108 and 108S. In someembodiments, the protective layer 118 is in direct contact with thesemiconductor dies 110A and 110B. In some embodiments, a portion of theprotective layer 118 is between the semiconductor die 110A and theshielding element 208.

In some embodiments, the material of the protective layer 118 isdifferent from that of the board 200. In some embodiments, theprotective layer 118 has a greater dielectric constant than that of theboard 200. In some embodiments, the protective layer 118 has a greaterdissipation factor than that of the board 200.

In some embodiments, the protective layer 118 is made of or includes amolding compound material. The molding compound material nay include apolymer material, such as an epoxy-based resin with fillers dispersedtherein. In some embodiments, a liquid molding compound material isintroduced or injected between the protective substrate 20 and thecarrier substrate 100. The liquid molding compound material may flowinto the openings G to encapsulate the semiconductor die 110A. A thermalprocess is then used to cure the liquid molding compound material and totransform it into the protective layer 118.

As shown in FIG. 1F, the carrier substrate 100 is removed, andconductive bumps 120 are formed, in accordance with some embodiments. Insome embodiments, the conductive bumps 120 are or include solder humpssuch as tin-containing solder humps. The tin-containing solder bumps mayfurther include copper, silver, gold, aluminum, lead, one or more othersuitable materials, or a combination thereof. In some embodiments, thetin-containing solder hump is lead free. In some embodiments, solderballs (or solder elements) are disposed onto the exposed conductivefeatures 106 after the removal of the carrier substrate 100. A reflowprocess is then carrier out to melt the solder balls into the conductivehumps 120. In some other embodiments, under bump metallization (UBM)elements are formed over the exposed conductive features 106 before thesolder balls are disposed. In some other embodiments, solder elementsare electroplated onto the exposed conductive features 106. Afterwards,a reflow process is used to melt the solder element to form theconductive bumps 120. In some embodiments, a singulation process is thencarrier out to saw through the formed structure. As a result, multipleseparate chip packages are formed. In FIG. 1F, one of the chip packagesis shown.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIGS. 8A-8C are cross-sectional views of various stages of aprocess for forming a chip package, in accordance with some embodiments.As shown in FIG. 8A, a structure similar to the structure shown in FIG.1C is provided or formed, in accordance with some embodiments.

In some embodiments, adhesive elements 802 are formed over thesemiconductor dies 110A and 110B before the protective substrate 20 isbonded to the conductive structures 108 and 108S, as shown in FIG. 8A.The adhesive elements 802 may include adhesive tapes, adhesive glue, orother suitable elements.

As shown in FIG. 8B, the protective substrate 20 is bonded to theconductive structures 108 and 108S, in accordance with some embodiments.In some embodiments, the protective substrate 20 is bonded to theconductive structures 108 and 108S through the conductive bumps 214 and214S. The adhesive elements 802 may assist in the bonding process toprevent misalignment and/or undesired displacement.

Afterwards, the processes the same as or similar to those illustrated inFIGS. 1E and 1F are used to form a chip package, as shown in FIG. 8C inaccordance with some embodiments.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 9 is a cross-sectional view of a chip package, inaccordance with some embodiments. In some embodiments, the chip packageincludes a single semiconductor die (the semiconductor die 110A) that issurrounded by the conductive structures 108S and the shielding element208.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 10 is a cross-sectional view of a chip package, inaccordance with some embodiments. In some embodiments, the chip packageincludes a single semiconductor die (the semiconductor die 110A) that issurrounded by the conductive structures 108S and the shielding element208. As shown in FIG. 10. the adhesive element 802 is formed between thesemiconductor die 110A and the shielding element 208.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 11 is a cross-sectional view of a chip package, inaccordance with some embodiments. In some embodiments, a structure thesame as or similar to the structure shown in FIG. 8C is provided orformed. Afterwards, the structure is bonded onto a circuit board 804. Insome embodiments, the circuit board 804 is a printed circuit board. Insome embodiments, the circuit board 804 includes a shielding element806.

Similar to the shielding element 208, the shielding element 806 may be aconductive plate, a conductive mesh, or a combination thereof. Theshielding element 806 may be used to further enhance shieldingefficiency. The conductive structures 108S (which together function as ashielding structure), the shielding element 208, and the shieldingelement ma together be used to prevent the electromagnetic wavegenerated by the semiconductor die 110A from affecting the operation ofnearby device elements, such as the semiconductor the 110B or anothernearby package

In some embodiments, the shielding element 208 is formed between theboard 200 and the semiconductor die 110A. However, embodiments of thedisclosure are not limited thereto. Many variations and/or modificationscan be made to embodiments of the disclosure. In some other embodiments,the shielding element is formed at another position.

FIG. 12 is a cross-sectional view of a chip package, in accordance withsome embodiments. In some embodiments, a shielding element 208′ isformed. The shielding element 208′ has a first portion positioned abovethe board 200 and a second portion penetrating through the board 200.Therefore, in these cases, the board 200 is positioned between the firstportion of the shielding element 208′ and the semiconductor die 110A.The first portion of the shielding element 208′ is electricallyconnected to the conductive structures 108S through conductive element214S and the second portion of the shielding element 208′. The materialand formation method of the shielding element 208′ may be the same as orsimilar to those of the shielding element 208 and/or the conductivefeature 206. Similar to the shielding element 208, the shielding element806 may be a conductive plate, a conductive mesh, or a combinationthereof.

Many variations and/or modifications can be made to embodiments of thedisclosure. FIG. 13 is a cross-sectional view of a chip package, inaccordance some embodiments. FIG. 13 shows a cross-sectional view of achip package that is similar to that shown in FIG. 11. In someembodiments, the chip package further includes one (or more) passivecomponent 902. The passive component 902 may include a resistor, acapacitor, an inductor, one or more other suitable elements, or acombination thereof.

Many variations and/or modification can be made to embodiments of thedisclosure. For example, the position and/or the number of the antennaelement may be modified. In some embodiments, some of the conductivefeatures 106 together function as an antenna element. In someembodiments, some of the conductive structures 108 function as anantenna element. In some embodiments, multiple antenna elements areformed.

Embodiments of the disclosure form a chip package with a shieldingstructure. One or more conductive structures are formed to surround anarea where a semiconductor die is designed to be positioned. Thesemiconductor die may include radio-frequency circuits and wouldgenerate electromagnetic wave during operation. The conductivestructures surround the semiconductor die and function as the shieldingstructure. Therefore, the generated electromagnetic wave may beprevented from negatively affecting the operation of nearby deviceelements. The quality and performance of the chip package aresignificantly improved.

According to some embodiments, a method for forming a chip package isprovided. The method includes forming a plurality of conductivestructures over a carrier substrate. The method also includes disposinga semiconductor die over the carrier substrate such that the conductivestructures surround the semiconductor die. The method further includesdisposing a shielding element over the semiconductor die and theconductive structures. The shielding element is electrically connectedto the conductive structures.

In some embodiments, the method further includes for a protective layerto surround the conductive structures and the semiconductor die andbonding a protective substrate to the conductive structures before theprotective layer is formed. In some embodiments, the method furtherincludes forming the shielding element over the protective substratebefore bonding the protective substrate to the conductive structures. Insome embodiments, the method further includes forming an antenna elementover the protective substrate. In some embodiments, the antenna. elementis formed over the protective substrate before bonding the protectivesubstrate to the conductive structures. In some embodiments, theprotective substrate is bonded to the conductive structures throughtin-containing solder elements.

In some embodiments, the method further includes introducing a polymermaterial between the protective substrate and the carrier substrate andcuring the polymer material to form the protective layer. In someembodiments, the method further includes forming a redistributionstructure over the carrier substrate before the conductive structuresare formed. In some embodiments, the method further includes removingthe carrier substrate and forming conductive bumps over theredistribution structure, wherein the redistribution structure isbetween the protective layer and the conductive bumps. In someembodiments, the method further includes disposing an additionalsemiconductor die over the carrier substrate before the protective layeris formed, wherein the additional semiconductor die is outside of anarea surrounded by the conductive structures. In some embodiments, theshielding element includes a conductive plate, a conductive mesh, or acombination thereof. In some embodiments, two of the conductivestructures are separated from each other by a distance, and the distanceis smaller than half a wavelength of an electromagnetic wave generatedby the semiconductor die.

According to some embodiments, a method for forming a chip package isprovided. The method includes forming a plurality of conductivestructures over a redistribution structure. The method also includesdisposing a semiconductor die over the redistribution structure suchthat the conductive structures surround the semiconductor die. Two ofthe conductive structures are separated from each other by a distance,and the distance is smaller than half a wavelength of an electromagneticwave generated by the semiconductor die.

In some embodiments, each of the conductive structures has a width in arange from about 5 μm to about ten times the distance. In someembodiments, the method further includes forming a protective layer tosurround the conductive structures and the semiconductor die and bondinga protective substrate to the conductive structures before theprotective layer is formed. In some embodiments, the method furtherincludes forming a shielding element over the protective substratebefore bonding the protective substrate to the conductive structures.

According to some embodiments, a method for forming a chip package isprovided. The method includes disposing a first semiconductor die and asecond semiconductor die over the a redistribution structure. The methodalso includes disposing a plurality of conductive structures over theredistribution structure. The conductive structures surround an areawhere the first semiconductor die is positioned, and the secondsemiconductor die is positioned outside of the area.

In some embodiments, two of the conductive structures are separated fromeach other by a distance, and the distance is smaller than half awavelength of an electromagnetic wave generated by the firstsemiconductor die. In some embodiments, the method further includesdisposing a shielding element over the first semiconductor die, and theshielding element is electrically connected to the conductivestructures. In some embodiments, the shielding element includes aconductive mesh having a plurality of through-holes, and each of thethrough-holes has a width that is smaller than half the wavelength ofthe electromagnetic wave generated by the first semiconductor die.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What s claimed is:
 1. A method for forming a chip package, comprising:forming a plurality of conductive structures over a carrier substrate;disposing a semiconductor die over the carrier substrate such that theconductive structures surround the semiconductor die; and disposing ashielding element over the semiconductor die and the conductivestructures, wherein the shielding element is electrically connected tothe conductive structures.
 2. The method as claimed in claim 1, furthercomprising: forming a protective layer to surround the conductivestructures and the semiconductor die; and bonding a protective substrateto the conductive structures before the a protective layer is formed. 3.The method as claimed in claim 2, further comprising forming theshielding element over the protective substrate before bonding theprotective substrate to the conductive structures.
 4. The method asclaimed in claim 2, further comprising forming an antenna element overthe protective substrate.
 5. The method as claimed in claim 4, whereinthe antenna element is formed over the protective substrate beforebonding the protective substrate to the conductive structures.
 6. Themethod as claimed in claim 2, wherein the protective substrate is bondedto the conductive structures through tin-containing solder elements. 7.The method as claimed in claim 2, further comprising: introducing apolymer material between the protective substrate and the carriersubstrate; and curing the polymer material to form the protective layer.8. The method as claimed in claim 2, further comprising forming aredistribution structure over the carrier substrate before theconductive structures are formed.
 9. The method as claimed in claim 8,further comprising: removing the carrier substrate; and formingconductive bumps over the redistribution structure, wherein theredistribution structure is between the protective layer and theconductive bumps.
 10. The method as claimed in claim 2, furthercomprising disposing an additional semiconductor die over the carriersubstrate before the protective layer is formed, wherein the additionalsemiconductor die is outside of an area surrounded by the conductivestructures.
 11. The method as claimed in claim 1, wherein the shieldingelement comprises a conductive plate, a conductive mesh, or acombination thereof.
 12. The method as claimed in claim 1, wherein twoof the conductive structures are separated from each other by adistance, and the distance is smaller than half a wavelength of anelectromagnetic wave generated by the semiconductor die.
 13. A methodfor forming a chip package, comprising: forming a plurality ofconductive structures over a redistribution structure; and disposing asemiconductor die over the redistribution structure such that theconductive structures surround the semiconductor die; wherein two of theconductive structures are separated from each other by a distance, andthe distance is smaller than half a wavelength of an electromagneticwave generated by the semiconductor die.
 14. The method as claimed inclaim 13, wherein each of the conductive structures has a width in arange from about 5 μm to about ten times the distance.
 15. The method asclaimed in claim 13, further comprising: forming a protective layer tosurround the conductive structures and the semiconductor die; andbonding a protective substrate to the conductive structures before theprotective layer is formed.
 16. The method as claimed in claim 15,further comprising forming a shielding element over the protectivesubstrate before bonding the protective substrate to the conductivestructures.
 17. A method for forming a chip package, comprising:disposing a first semiconductor die and a second semiconductor die overthe a redistribution structure; and disposing a plurality of conductivestructures over the redistribution structure; wherein the conductivestructures surround an area where the first semiconductor die ispositioned, and the second semiconductor die is positioned outside ofthe area.
 18. The method as claimed in claim 17, wherein two of theconductive structures are separated from each other by a distance, andthe distance is smaller than half a wavelength of an electromagneticwave generated by the first semiconductor die.
 19. The method as claimedin claim 17, further comprising disposing a shielding element over thefirst semiconductor die, wherein the shielding element is electricallyconnected to the conductive structures.
 20. The method as claimed inclaim 19, wherein the shielding element comprises a conductive meshhaving a plurality of through-holes, and each of the through-holes has awidth that is smaller than half the wavelength of the electromagneticwave generated by the first semiconductor die.